Motorized pump

ABSTRACT

A motorized pump including a motor and a pump around the motor. The pump rotor is integrated with the motor rotor, wherein the pump rotor has vanes. The motorized pump may be employed as an electrical submersible pump (ESP) in a wellbore.

TECHNICAL FIELD

The present techniques relate to a pump integrated with a motor.

BACKGROUND

A pumping apparatus can include a hydraulic pump and electric motor astwo separate components coupled via a rotating shaft. Pumps may bepositive-displacement such as hydrostatic, gear, screw, diaphragm, etc.,or non-positive-displacement such as hydrodynamic, centrifugal,propeller, etc. A pump is typically associated with an electric motor.Electric motors can be powered by direct current (DC) sources, such asfrom batteries, motor vehicles, or rectifiers, or by alternating current(AC) sources, such as a power grid, inverters, or generators.

An electrical motor may operate through interaction of the motormagnetic field with motor winding currents to generate force. The motormay include a motor stator and a motor rotor. The term “stator” isderived from the word stationary. The stator may be a stationaryelectrical component having a group of individual electro-magnetsarranged in such a way to form a hollow cylinder, with one pole of eachmagnet facing toward the center of the group. The term “rotor” isderived from the word rotating. The rotor may be the rotating electricalcomponent having a group of electro-magnets arranged around a cylinder,with the poles facing toward the stator poles. In some examples, therotor may be located inside the stator and mounted on the motor shaft.These motor components can make the rotor rotate which in turn mayrotate the motor shaft. This rotation may occur because of the magneticphenomenon that unlike magnetic poles attract each other and like polesrepel.

Thus, the motor rotor may be a moving component of the electromagneticsystem in the electric motor. In particular, the interaction between thewindings and magnetic fields produces a torque around the axis of themotor rotor to rotate the motor rotor. This force may rotate the shaftthat couples the motor with the discrete pump.

A pump may be a submersible pump which is coupled to a submersible orhermetically-sealed motor separate from the pump body. The assembly maybe submerged in the fluid to be pumped and thus generally avoid pumpcavitation. Submersible pumps typically push the pumped fluid to thesurface. Applications of submersible pumps include drainage, sewagepumping, sewage treatment plants, general industrial pumping, slurrypumping, pond filters, seawater handling, fire-fighting, water well anddeep well drilling, offshore drilling rigs, artificial lifts, minedewatering, and irrigation systems. Submersible pumps may be lowereddown a borehole and used for residential, commercial, municipal andindustrial water extraction, and in water wells and oil wells. Lastly,for a submersible pump system, a seal section or protector is typicallydisposed between the pump and motor for motor protection. The protectormay absorb the thrust load from the pump, transmit power from the motorto the pump, equalize motor internal and external pressures, and preventwell fluids from entering the motor.

SUMMARY

An aspect relates to a motorized pump having a motor with a motor rotorand a motor stator, the motor stator having windings. The motorized pumpincludes a pump surrounding the motor. The pump has a pump rotorintegrated with the motor rotor, wherein the pump rotor includes vanes.

Another aspect relates to a motorized pump having a motor with a motorrotor and a motor stator, the motor stator having windings. Themotorized pump includes a pump radially enclosing the motor. The pumphas a pump rotor integrated with the motor rotor, wherein the pump rotorincludes vanes.

Yet another aspect relates to a method of operating an electricalsubmersible pump (ESP) having a motorized pump. The method includespumping, by the motorized pump, fluid from a wellbore. The motorizedpump includes a motor and a pump that radially encloses the motor,wherein the motor has a motor rotor and a motor stator. The pump has apump rotor with vanes and is integrated with the motor rotor.

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features andadvantages will be apparent from the description and drawings, and fromthe claims.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a diagram of a motorized pump.

FIG. 2 is a diagram of production site including an electricalsubmersible pump (ESP) motorized pump in a wellbore.

FIG. 3 and FIG. 3A are respective diagrams of different motorized pumps.

FIG. 4 is a perspective view of a helical-axial pump stator and rotor.

FIG. 5 is a diagram of a motorized pump which may have an external rotormotor.

FIG. 5A is a diagram of a motorized pump which may have an externalrotor motor.

FIG. 6 is a diagram of a general representation of an outer rotortechnology.

FIG. 7 is a diagram of a general representation of an inner rotortechnology.

FIG. 8 is a diagram of a motorized pump without an outer housing.

FIG. 9 is an end diagram of a layered representation of a motorizedpump.

FIGS. 10-13 are diagrams of motorized pumps that are multi-stagecentrifugal pumps.

FIG. 13A is a perspective view of a hydraulic element of a motorizedpump.

FIG. 14 is a block flow diagram of a method of operating an ESP having amotorized pump.

DETAILED DESCRIPTION

A submersible pump system may have both downhole components and surfacecomponents. The downhole components may include a motor, seal(protector), pump, and cable. Additional downhole components may includedata acquisition instrumentation, motor lead extension, cable bands, gasseparator, and check and drain valves. The surface components mayinclude a transformer, electrical junction box, and motor controllersuch as a variable speed controller.

Submersible pumps in oil production may provide for “artificial lift.”These pumps are typically electrically powered and commonly referred toas an electrical submersible pump (ESP). The ESP pump may be relativelylong and slender, and may be disposed in wellbores to lift or pumpfluids from the wellbores. Some ESP systems can fit and operate inwellbore casings as small as 4.5-inch outside diameter. ESPs can becentrifugal pumps operated in a vertical position, deviated position, orhorizontal position. As discussed below, the pump may be composed ofseveral impellers, blades, diffusers, vanes, etc. that apply head to andmove the fluids within the well.

ESPs can be an electro-hydraulic system having a centrifugal pump andelectric motor in addition to a sensory unit and a power delivery cable.The power delivery cable supplies the motor with electrical power fromthe surface. The motor converts electric power to mechanical power todrive the pump via a shaft or other components. The pump lifts anddischarges well fluids to the surface.

A centrifugal pump may be so named because the head added to fluid isdue at least in part to centrifugal effects. By stacking impellers anddiffusers (multi-staging), the desired lift or total dynamic head (TDH)may be achieved. Indeed, the pump may have stages made up of impellersand diffusers. The rotating impeller adds energy to the fluid as kineticenergy, whereas the stationary diffuser converts the kinetic energy offluids into head. The pump stages are typically stacked in series toform a multi-stage system contained within a pump housing. The headgenerated by each individual stage may be summative. Hence, the totalhead developed by the multi-stage system generally increases from thefirst to the last stage. ESP systems may employ a centrifugal pump belowthe level of the reservoir fluids. Moreover, submersible pumps may be asingle-stage pump or a multi-stage pump. For instance, ESPs can bemultistage centrifugal pumps operated in a vertical position.

In operation, the ESP receives the well fluids, applies artificial liftby spinning the impellers (vanes) on the pump shaft to apply pump headon the surrounding fluids to force the fluids toward the surface. Insome instances, the ESP can lift more than 25,000 barrels of fluids perday. ESP systems can pump a variety of fluids. Common fluids pumped areproduction fluids such as crude oil and brine. The pumped fluids mayinclude oil, gas, natural gas, liquid petroleum products, disposal andinjection fluids, solids or contaminates, carbon dioxide (CO2) andhydrogen sulfide (H2S) gases, treatment chemicals, and so forth. SomeESPs can handle corrosive fluids, abrasive contaminants such as sand,downhole temperatures, levels of gas production, and so on. ESPs may bedeployed in vertical, deviated, and horizontal wells.

As for installation, the downhole components of the ESP system may beinstalled via the bottom of the tubing string. Indeed, the ESP systemelectric motor and pump, such as a multistage centrifugal pump, may berun on a production string and connected back to a surface controlmechanism and transformer via the electric power cable. As mentioned, anelectric cable generally runs the length of the well, connecting thepump to a surface source of electricity.

An ESP can pump intermittently or continuously. An ESP can be adapted toautomation and control systems, and generally includes a surface controlpackage. Numerous surface control and communication devices aregenerally available for an ESP pump. The controller can be weatherproofand situated outdoors, or an indoor version placed in a building orcontainer. The control equipment can be located near the wellhead or upto several miles away.

ESP legacy technology may face at least two challenges: reliability andintervention cost. Low reliability may be attributed to the systemcomplexity both mechanically and electrically, compounded by the harshoperating environments. Intervention costs may be due to rig dependencyfor system deployment, retrieval, and replacement. The rig dependencymay be partially due to the ESP system length.

In contrast, embodiments herein improve reliability and provide forrigless deployment. In some examples, component functionalities areeliminated or combined to achieve better reliability. For instance,certain implementations eliminate the protector section by employingmagnetic coupling between the motor and pump. Embodiments combine themotor with the pump to give a motorized pump where the motor and thepump are built as one combined unit.

The present disclosure includes a pumping apparatus with a motorenclosed within. Unlike a conventional pumping system where the pump andthe motor are separated components linked together with a shaft (and intypical downhole applications having a protector section sitting inbetween for motor protection), certain embodiments herein provide forthe pump and the motor integrated as one unit, and without a shaft or aprotector section. Radially for some embodiments, from inside tooutside, the system may be made of the motor stator, the motor rotor andpump rotor, the pump stator, and the housing. The motor stator haswindings and can be energized with direct current (DC), or one-phase orthree-phase alternating or alternative current (AC). The motor rotor canbe an induction type design having steel laminations with copper barsand end ring. Alternatively, the motor rotor can be a permanent magnetdesign with steel laminations having permanent magnets mounted on aninside diameter (ID), or embedded within, to engage electromagneticallywith the motor stator.

In certain implementations, the outside diameter (OD), or OD portion, ofthe motor rotor is constructed with or integrated with a pump rotor. Thepump rotor has hydraulic elements such as vanes or helical vanes. Themotor rotor together with the pump rotor rotates within the pump stator.The pump stator also has hydraulic elements such as helical vanes on theID to engage hydraulically (also mechanically for positive displacementpump design) with the pump rotor vanes to pump fluids.

The techniques may include an external-rotor motor design andintegration with a pump. The pump and motor may be contained within ahousing. In all, advantages may include higher motor torque capability,larger pump OD to have a higher head generation capability, systemcompactness, and so on.

The pump system can be manufactured for surface use or for downholeapplications. The pump can be a positive displacement type orcentrifugal type. Positive displacement types include screw pump,progressive cavity pump, etc. Centrifugal types include multi-stagecentrifugal pump, helico-axial pump, etc. Again, the motor can be aninduction motor or permanent magnet motor. For downhole applications,the system can be deployed with a rig at the end of the tubing orriglessly with the power cable inside the tubing, and the like. Themotorized pump may have be have a reduced string length which mayfacilitate rigless operation to be carried out and without killing thewell. The disclosure gives innovative techniques to unify motor andpump, and which may simplify system configurations.

In summary, embodiments of the present techniques include a motorizedpump having a pump and motor integrated as a single (combined) unit. Themotor rotor may be constructed with or integrated with the pump rotor.In some examples, the motor rotor together with the pump rotor rotateswithin the pump stator. The motor may have an external rotor motorconfiguration and is within the pump. In certain implementations, thepump may surround or enclose the motor. Radially, from inside tooutside, the unit may include: (a) motor stator, (b) motor rotor andpump rotor, (c) pump stator, and (d) a housing. If a housing isemployed, the pump and motor are contained within the housing. The pumprotor has hydraulic elements such as vanes or helical vanes. The pumpstator has hydraulic elements, such as vanes or helical vanes, on itsinside diameter (ID) to engage hydraulically with the pump-rotorhydraulic elements to pump fluids. This engagement may be mechanical forpositive displacement pumps.

Turning now to the drawings, FIG. 1 is a motorized pump 100 having apump 102 and a motor 104 as an integrated unit. The pump 102 can be apositive displacement pump or a centrifugal pump, and the like. Themotor 104 may be an induction motor, permanent magnet motor, and soforth. The motor 104 may include a motor stator and a motor rotor. Themotor 104 may drive the pump 102.

In examples, the pump rotor is the motor rotor or is integrated with themotor rotor. For example, pump hydraulic elements, such as vanes, canreside on the motor rotor to make the motor rotor both a motor rotor anda pump rotor. Thus, in examples, the motor rotor and pump rotor mayeffectively be the same overall component.

Moreover, in some embodiments, the pump 102 is radially to the outsideof the motor 104. Indeed, the pump 102 may cylindrically or radiallysurround the motor 104. In the illustrated embodiment, the pump 102encloses the motor 104. See also, for example, FIGS. 5, 8, 9, and 13.

In other embodiments, the motor 104 may be radially to the outside ofthe pump 102. See, for example, FIGS. 3 and 11. In those embodiments,the motor 104 may surround or enclose the pump 102.

In FIG. 1, in operation, the fluid to be pumped is received, asindicated by arrow 106, at an inlet such as a suction or intake. Thepump 102 discharges the pumped fluid, as indicated by arrow 108. Thepump 100 system may be an electrical submersible pump (ESP) system. Thepump system 100 includes additional components 110, such as surfacecomponents. ESP pump 100 systems may consist of both surface components110 such as those housed in the production facility or oil platform, andsubsurface components such as the integrated pump 102 and motor 104 inthe well hole or wellbore.

The ESP that employs the motorized pump 100 may be labeled as an ESPsystem and which pumps or lifts fluid from a well or wellbore. The fluidmay be or include hydrocarbon such as oil and gas. The ESP motorizedpump 100 can be sized and arranged for insertion downhole into awellbore. Depending on the application, the motorized pump 100 may besized to fit into a wellbore casing having an outer diameter as small as4.5 inches. Furthermore, the pump 102 and motor 104 may be sized to liftthe volume of fluid production from the wellbore. Moreover, the motor104 may be powered from the surface via, for example, a submersibleelectric cable.

In some examples, the pump 102 is a centrifugal pump or a multi-stagecentrifugal pump. Again, the pump 102 typically has an inlet as anintake or fluid suction. The inlet may have an intake screen in someembodiments. In operation, fluids enter the pump 102 through the inlet.Thus, the pump 102 receives fluid through the inlet and discharges 108the pumped fluid from an opposite end on an upper portion of the pump102. Fluid or liquids accelerated by the hydraulic element, such as apump rotor or impeller, may lose kinetic energy in a stationary elementor diffuser where a conversion of kinetic energy to pressure energytakes place. The fluids are lifted by the pump stage or stages. OtherESP motorized pump 100 parts may include radial bearings or bushingsthat provide radial support, thrust bearings, and so on.

FIG. 2 is an oil and gas production site 200 including a hole orwellbore 202 drilled into the Earth 204 (formation). A wellbore casing206 is positioned in the wellbore 202. The casing 206 may have holes,slots, or perforations 208 to receive hydrocarbon fluid 210, such as oiland gas, from the formation. In the illustrated embodiment, themotorized pump 100 as an ESP integrated pump/motor 100 is lowered as adownhole component into the wellbore casing 206. In operation, the ESPintegrated pump/motor 100 receives the hydrocarbon fluid 210, appliespump head to the fluid 210, and discharges the fluid 210 through aproduction conduit 212 toward the Earth surface 214, as indicated byarrow 216. As discussed, an ESP motorized pump 100 system generallyincludes a pump fluid intake or inlet. The motorized pump discharge mayinclude protective devices, such as a check valve, drain valve, etc. Inaddition, ESP downhole components may include a cable, cable guard,cable clamps, gas separator, sensor and data acquisitioninstrumentation, and so forth.

The ESP surface components 218 of the ESP motorized pump 100 may includesurface controls. Indeed, an ESP 100 typically has the surface equipment218 such as an electrical transformer and system controller. Some ESPmotorized pump 100 examples include a variable frequency drive. Also,ESP motorized pump 100 components may include a motor lead extension inaddition to the power cable. For instance, an electrical main cable anda cable motor-lead extension may connect surface equipment with the ESPmotor 104 and a well-monitoring device. A monitoring submersible toolmay be installed onto the motor to measure parameters such as pumpintake and discharge pressures, intake and motor oil temperature, andvibration. Measured downhole data may be communicated to the surface viathe power cable.

Some ESP motorized pump 100 examples may include a gas handler or gasseparator at or near (or combined with) the pump intake or inlet 106.Gas separators may be employed where free gas causes interference withpump performance. The gas separator may separate some free gas from thefluid stream entering the pump to improve pump performance. Yet, in someexamples of the pump 102 as a helico-axial pump with higher rotationspeed, for example, 4000 revolutions per minute (rpm) or greater, andwith no radial or mixed-flow pump, a gas separator can be avoided incertain embodiments. Indeed, some ESP motorized pump 100 embodimentswith a helico-axial pump 102 and permanent magnet motors 104 do not havethis gas separator because significant benefit may not be realized incertain instances with the gas separator. Some examples of ahelico-axial pump 102 can function as a compressor and handle, pump, andprocess fluid with high gas volume fraction such as greater than 70percent (%).

FIG. 3 is a motorized pump 300 with the motor and the pump built as onecombined unit. In this example, the combined unit is housed inside ahousing 302 such as a steel housing. Within the housing, the pump systemis driven by and encased within the motor.

The motor stator 304 has laminations, such as steel laminations,compressed together. Slots are cut within the laminations to facilitateinstallation of magnetic coils. In operation, once the stator 304 isenergized, rotating magnetic fields may be generated. Laminations may bethe steel portions of a motor stator and rotor, and composed of thinlamination sheets stacked together. These laminations can be stacked“loose,” welded, or bonded together depending on the application. Insome examples, the motor stator or rotor can be solid piece. However,the motor stator or rotor may instead more typically be the motorlaminations sheets, for example, to reduce eddy current losses.

The motorized pump 300 includes an integrated motor rotor 306 and pumprotor 306. The motor rotor 306 portion of this integrated motorrotor/pump rotor 306 can be an induction type design with bars, such ascopper bars, installed within the stack of steel laminations and shortcircuited with end rings. Another option is for the motor rotor 306 toemploy permanent magnets 308, as illustrated in FIG. 3. These permanentmagnets 308 of the motor rotor 306 engage magnetically with the rotatingmagnetic fields of the motor stator 304 such that torque and rotation ofthe motor rotor 306 is generated.

Again, the motor rotor 306 is integrated with the pump rotor 306. Inother words, the interior side or portion of the motor rotor 306 may bethe pump rotor 306. Indeed, on the interior surface of the motor rotor306 are hydraulic elements 310, such as vanes or helical vanes, built onthe surface as pump elements, making the motor rotor 306 and the pumprotor 306 an integral unit.

In the illustrated example, the stationary pump stator 312 is situatedat the center of the motorized pump 300 unit. The external surface ofthe pump stator 312 is built with corresponding hydraulic elements, suchas helical vanes, which engage hydraulically with the pump rotor 306hydraulic elements to move or pressurize, or apply head to, fluids beingpumped such as production fluids.

Further, the depiction in FIG. 3 is two hydraulic stages of the pump300. The motorized pump 300 system can be built with multiple motor/pumprotors (more than two) to meet the pumping requirement. The pump 300 caninclude respective radial bearings 314 between adjacent rotors. The pumpillustrated in FIG. 3 is a helico-axial centrifugal pump. However, thecurrent disclosure is not limited to a helico-axial centrifugal pump butcan be another type of centrifugal pump, a screw pump, progressivecavity pump, and so on. The motorized pump 300 includes a power cable316 to supply power to the motor.

The flow of pumped fluid through the motorized pump 300 is indicated byarrows 318 as entering the depicted inlet or upstream stage and byarrows 320 as discharging from the depicted outlet or downstream stage.Lastly, in certain embodiments of the motorized pump 300 as an ESP, thepump stator 312 can be hollow and can incorporate a nipple profilefacilitating the hollow passage to be blocked during production and openfor well logging or stimulation.

FIG. 3A is a motorized pump 330 (two stages depicted) having a motor andpump within a housing 332. The motor stator 334 has laminations andmagnet wire windings. The pump stator 336 with vanes 338 is installedinside the motor stator 334 and integrated with or attached to the motorstator 334. The pump stator 336 and the vanes 338 may be constructed ofmetals and other materials. Similarly, the pump rotor 340 and pump rotorvanes 342 may be constructed of metals and other materials. The pumprotor 340 is integrated or attached to the motor rotor 344 which, inthis example, is situated at the center of the system. The motor rotor344 is made with stacks of laminations and with multiple high-strengthpermanent magnets 346 (for example, samarium cobalt or neodymium)embedded within. Once the motor stator 334 is energized, its rotatingmagnetic fields will drive the motor rotor 344 to rotate, and fluids canbe pumped. The material of the pump stator 336, rotor 340 and vanes maypromote electromagnetic coupling and cooling due to heat conductivecharacteristics.

The motorized pump 330 includes a power cable 346 to supply power to themotor. The pump 330 can included radial bearings 348 between adjacentrotors of the two depicted stages. Moreover, the flow of pumped fluidthrough the motorized pump 300 during operation is indicated by arrows350. Lastly, FIG. 4 is a typical helical-axial pump 400 stator 402 androtor 404 and in which its principal of operation may be incorporated inthe motorized pump 300 of FIG. 3 or the motorized pump 330 of FIG. 3A.

A potential drawback with various embodiments of FIG. 3 or FIG. 3A isthe pump OD may be limited because the pump is internal of the motor.These configurations of the pump inside the motor may be due, at leastin part, to employment of the motor as an internal rotor motor. Otherembodiments, such as that depicted in FIG. 5, employ an external rotormotor. FIGS. 5 and 5A are motorized pumps that employ an external rotormotor.

FIG. 5 is a motorized pump 500 with the motor and pump as one unit.Again, the motor in the illustrated embodiment is an external rotormotor. The motorized pump 500 includes a housing 502, a pump stator 504with vanes (for example, helical vanes), and a motor stator 506 withlaminations and windings. The pump stator 504 is not in a lockedposition with the motor stator 506.

The motorized pump 500 includes a motor rotor 508 and a pump rotor 510with vanes integrated with the motor rotor 508. Permanent magnets 512are disposed on the motor rotor 508. In examples, at the center of themotorized pump 500 unit is the motor stator 506 which can be made of astack of steel laminations compressed together, and within theselaminations, slots cut for magnetic wire windings. In operation, aselectric power is supplied to the motor stator 506 windings, rotatingmagnetic fields may be generated.

In the illustrated embodiment of FG. 5, the motor rotor 508 radiallyencloses the motor stator 506. This configuration can be characterizedas turning a typical or conventional motor inside out. Further, the pumpand motor are radially arranged, as opposed to the conventional axialarrangement. Moreover, the pump (including the pump stator 504 and thepump rotor) radially encloses or surrounds the motor (including themotor stator 506 and the motor rotor 508). While only two hydraulicstages (centrifugal pump stages) are depicted in FIG. 5 for clarity, themotorized pump 500 can have more hydraulic stages (in the axialdirection).

Further, at the bottom in the axial direction, the motorized pump 500may have an intake (not shown) disposed radially across completing themotorized pump 500 and that receives the fluid 518 (for example,production fluid) to be pumped. In addition, at the top in the axialdirection, the motorized pump 500 may have a discharge head disposedradially across completing the motorized pump 500 and that discharge thepump fluid 520 (for example, production fluid) exiting the motorizedpump 500.

FIG. 5 depicts the motor rotor 508 with permanent magnets 512. However,the motor rotor 508 can instead be an induction type with copper barsinside a stack of steel laminations and short circuited with end rings.Yet, the motor may generally be more compact with permanent magnets 512.Electromagnetic interaction between the motor stator 506 magnetic fieldsand the permanent magnets 512 generates torque and rotation.

The OD or external surface of the motor rotor 508 has vanes, such ashelical vanes, resulting in an integral motor rotor 508 and pump rotor510. As the rotor rotates, these vanes engage hydraulically with thecorresponding vanes on the stationary pump stator 504 to move or applypump head to the pumped fluids such as production fluids. With the pumpgenerally including radially outside of the motor, some embodimentsassociated with FIG. 5 can provide a relatively larger pump OD,enhancing pump hydraulic-head generation.

In addition, with the motor stator 506 at the center, the configurationmay lend to rigless cable deployment. The concentricity of the cable andthe motor stator 506 facilitates easy make-up between the two componentsfor rigless cable deployment.

The motorized pump 500 may include a radial bearing 514 disposed axiallybetween the rotors of the two adjacent stages. Further, a power cable516 is typically included to supply power to the motor. For themotorized pump 500 as an ESP, power may be supplied via the power cable516 from the surface. In operation, pumped fluid (production fluid)flows though the motorized pump 500 stages, as indicated by arrows 518and 520.

Again, the motor rotor 508 and pump rotor 510 are integrated. Forinstance, the motor rotor 508 and pump rotor 510 effectively share thesame rotor in certain examples. Indeed, the permanent magnets of themotor rotor 508 and the vanes of the pump rotor 510 are both on thelaminations of the motor rotor 508.

The pump rotor 510 vanes are typically machined. Also, for someembodiments, pump vanes are not positioned within the passage of themotor stator 506 but instead are radially outside of the motor stator506.

FIG. 5A is a motorized pump 530 that also employs an external rotormotor. The pumped fluid flow 532 through the pump 530 may be similar tothe pumped fluid flow through the motorized pump 330 of FIG. 3A. In FIG.5A, the motorized pump 530 includes a pump stator 534 with vanes. Thepump stator 534 is attached to the motor stator 536. Indeed, the pumpstator 534 vanes are integrated with the motor stator 536. The motorstator 536, which has laminations and windings, is in the center of themotorized pump 530. The pump rotor 538 with vanes 540 is attached to(integrated with) the motor rotor 542 which has laminations andpermanent magnets 544. In some examples, the pump stator 534, rotor538/542, and/or vanes may be constructed of heat conductive metal.

As indicated, an aspect of embodiments of FIG. 5 and FIG. 5A is anexternal rotor motor. In some examples, the motor stators 506 and 536have laminations, slots, and magnet wires with the windings of themagnet wires configured such that the electromagnetic fields projectoutward for effective engagement with the external rotor.

Compared with rotor-centric permanent magnet motors, the external rotormotor topology where the rotor rotates on the outside of the stator mayhave a greater magnetic flux, resulting in higher power density orhigher torque density. This higher density in some examples mayfacilitate the motor to be smaller and thus the pump to be larger whereradially limited such as downhole.

FIG. 6 is a general representation 600 of outer rotor technology with anouter rotor permanent magnet motor. FIG. 7 is a general representation700 of inner rotor technology with an inner rotor permanent motor.

FIG. 8 is a motorized pump 800 having a pump around a motor, and whichmay be a variation of the pump 500 of FIG. 5 without the housing 502. Inthis example, the pump stator 804 (with vanes) has sufficient strengthto withstand the pressure and tensile load for downhole applications.For example, the pump stator 804 may be high-strength material withsufficient wall thickness. In downhole applications, radial dimensioncan be limited. The motorized pump 800 without an outer housing mayfacilitate the pump to have a larger outside diameter within a limitedradial dimension of a wellbore, leading to higher flow rates andhead-generation capability. In the illustrated embodiment, the pumpstator 804 is the outer layer of the motorized pump 800.

The motorized pump 800 has motor stator 806 with laminations andwindings, an integrated motor/pump rotor 808 having pump rotor vanes 810and motor-rotor permanent magnets 812. The motorized pump 800 has radialbearings 814 and a power cable 816. The motorized pump 800 may bedownhole components (motor and pump) of an ESP system without a housing.

FIG. 9 is a radial cross-section representation of a motorized pump 900depicting subcomponents as layers to note relative position. The pumpsurrounds or encloses the motor. The motorized pump 900 includes a keyor O-ring 902 to lock the pump rotor 904 with the motor rotor 906. Themotor rotor 906 may have permanent magnets or an induction design. Themotor rotor 906 can be a squirrel cage induction type. The motorizedpump has a motor rotor bore 908 and pump rotor vanes.

The motorized pumps in FIGS. 3, 3A, 5, 5A, and 8 are multi-stage pumpswith only two of the stages depicted for clarity. Moreover, in examplesof these motorized pumps in FIGS. 3, 5, and 8, an air gap between motorstator and motor rotor is not used for pumping or flowing pump fluidthere through. In other words, in those embodiments, the pumped fluidpassage is not between the motor stator and the motor rotor. However,the examples depicted in FIGS. 3A and 5A may use this air gap forpumping. In addition, examples of the motorized pumps of FIGS. 3, 3A, 5,5A, 8, and 9 do not include diffusers. Further, the motorized pumpsdepicted in FIGS. 3, 3A, 5, 5A, 8, and 9 may be a downhole motor andpump of an ESP and without an ESP protector or motor protector.Protective devices, such as a check valve, drain valve, etc. may belocated above the motorized pump 300, 330, 500, 530, 800, 900 dischargein an ESP system. In examples, the check valve may close on shut down ofthe motorized pump. Lastly, examples of the motorized pumps do not havean integral canned electrical motor, generally or for surfaceapplications.

The ESP system components may include the motorized pump 300, 330, 500,530, 800, 900 and surface components 110, 218 such as surface controls.As discussed, the ESP may have surface components disposed at the Earthsurface. A tubing head may support the downhole tubing provide a sealfor the power cable to pass through the wellhead. The surface components(for example, components 110, 218) of the motorized pump 100, 300, 330,500, 530, 800, 900 as an ESP system may include fixed-speed orvariable-speed controllers and drives.

In certain embodiments, a smart or intelligent remote terminal unit(RTU) programmable controller (for fixed-speed or variable-speed)maintains flow of electricity to the motorized pump. The control packagemay facilitate the well to operate continuously or intermittently, or beshut off, provide protection from power surges or other electricitychanges, and the like. A variable speed drive (VSD) may provide ESPsystems substantially continuous duty-variable flow and pressurecontrol.

In some embodiments, the power cable is connected to a top portion ofthe motor. The power cable may be strapped to the outside of theproduction tubing from the motor to the surface of the well, and extendon the surface to, for example, a control junction box. Power cables mayhave a metal shield to protect the cable from external damage.Electricity is typically provided to the site by a commercial powerdistribution system. ESP surface components may include an electricalsupply system. In some examples, a transformer may convert theelectricity provided via commercial power lines to match the voltage andamperage of the ESP motor.

Cables for sensor and control data may also be included. A submersiblepump cable may be a product used for a submersible pump in a deep well.The size and shape of submersible pump cable can vary depending on theusage and pump instrument. Some types of pump cables include controlwires as well as power conductors for the pump motor.

The ESP system may include a downhole sensor and companion surfaceinterface unit to provide for retrieval of real-time system and wellboreperformance parameters. Multi-data channel sensors can measure intakepressures, wellbore and motor winding temperature, pump dischargepressure, vibration, current leakage, and flow rate. ESP system controland alarms may be implemented via real-time monitoring of downholereadings. Surface interface can be accomplished via permanent digitalreadout, handheld data logger, or laptop computer, and so on. Remotemonitoring of data from web-based computers is implemented in certainexamples.

In general, the electrical submersible motorized pump as an ESP, maygive artificial-lift for lifting moderate to high volumes of fluids fromwellbores. These volumes may range from a low of 150 barrels/day (B/D)or 24 cubic meter/day (m3/d) to as much as 75,000 B/D or 12,300 m3/d.The aforementioned variable-speed controllers can in some arrangementsextend the range.

The ESP may include a gas handling system which may reduce the free gasentering the pump. The gas handling system may include or be associatedwith a gas avoider, a gas separator such as a rotary and vortex gasseparator, or gas handler such as a helico-axial gas handler.

Furthermore, the motor of the motorized pump 500 may be an induction(asynchronous) motor with the electromagnetic system including the motorstator 506 and motor rotor 508. One example is a squirrel-cage inductionmotor. The squirrel-cage rotor may have laminated steel in the core withbars, for example, evenly spaced bars of copper or aluminum. The barsmay be slanted, or skewed, to reduce magnetic hum and slot harmonics inthe assembly. The generated torque forces motion through the rotor tothe load. Another example is wound rotor which may be a cylindrical coremade of steel lamination with slots to hold the wires for its 3-phasewindings.

In a three-phase induction machine, alternating current supplied to themotor stator windings energizes the stator to create a rotating magneticflux. The flux generates a magnetic field in the air gap between themotor stator and the rotor and induces a voltage which produces currentthrough the motor rotor bars. The motor rotor circuit is shorted andcurrent flows in the rotor conductors. The action of the rotating fluxand the current produces a force that generates a torque to drive themotor and thus drive the pump.

The discussion now turns to FIGS. 10-13 which are embodiments ofmotorized pumps that are multi-stage centrifugal pumps with radialintegration of diffuser, motor, and impeller. Again, each of themulti-stage centrifugal pumps depicted in FIGS. 10-13, respectively, maybe a motorized pump 100. In FIGS. 10-13, the motorized pump may be anESP motorized pump without a motor protector. The multi-stagecentrifugal pumps depicted in FIGS. 10-13 are shown with only one of thestages for clarity.

FIG. 10 is a motorized pump 1000 having a multi-stage centrifugal pump.The motorized pump 1000 includes a housing 1002 and a shaft 1004. Inembodiments, the shaft 1004 does not rotate in operation. The motorizedpump 1000 includes a motor stator 1006 having laminations and windings,a pump diffuser 1008 (stationary), and a pump impeller 1010 withpermanent magnets 1012. The motor stator 1006 radially surrounds thepump diffuser 1008 and the pump impeller 1010. In other words, the motorstator 1006 radially surrounds (encloses) the centrifugal pump. Inoperation, the permanent magnets 1012 on the impeller 1010 engage themotor stator 1006 for rotation of the impeller 1010.

The diffuser 1008 may be characterized as an internal diffuser 1008 inthat the diffuser 1008 is adjacent the shaft 1004. The impeller 1010 maybe characterized as an external impeller 1010 in that the impeller 1010is adjacent the motor stator 1006, or in the sense that at least aportion of the impeller 1010 is radially to the outside of the internaldiffuser 1008. Both the impeller 1010 and diffuser 1008 each havemultiple vanes, though the vane geometries can be different.

The depiction in FIG. 10 is a simplified representation for clarity.While the internal diffuser 1008 may have a shape or features of animpeller, the diffuser 1008 vane geometry is configured to promotehydraulic flow and for pump efficiency. For example, the total flow areafrom entry to exit of the diffuser 1008 will be increasing to allow flowto slow down. The external impeller 1010 may have a shape or features ofa diffuser but the impeller 1010 including impeller flow path and vanegeometry promote hydraulic flow and pump efficiency. With respect to theinternal diffuser 1008 and the external impeller 1010, the detailed vangeometries (e.g., exit angle, flow areas) may be different because theirfunctions are different. A function of the external impeller 1010 may beto accelerate the pump fluids to provide the fluids with kinetic energy.A function of the internal diffuser 1008 may be to slow down the fluidsand transfer the kinetic energy to pump head or pressure.

In operation, as indicated, the pump impeller 1010 is made to rotateutilizing the electromagnetic coupling between the permanent magnets1012 installed on the pump impeller 1010 with the magnetic fields of themotor stator 1006. The magnetic fields of the motor stator 1006 aregenerated by electrical power delivered with the power cable 1014. Inembodiments, the external impeller 1010 is magnetic with permanentmagnets 1012 disposed on at least a portion of the impeller 1010 body.

FIG. 11 is a motorized pump 1100 having a multi-stage centrifugal pump.The motorized pump 1100 has a housing 1102 and shaft 1104. In examples,the shaft 1104 does not rotate in operation. The motorized pump 1100includes a motor having an annular motor rotor 1105 and a motor stator1106. The motor stator 1106 has laminations and windings. The motorizedpump 1100 has a power cable 1114 to supply power to the motorized pump1100, such as from the Earth surface to the motorized pump 1100 employeddownhole as an ESP motor/pump

The motorized pump 1100 includes a pump having a pump diffuser 1108(stationary) and a pump impeller 1110. The pump impeller 1110 ismechanically engaged with the motor rotor 1105 which has permanentmagnets 1112. In the illustrated embodiment, the multi-stage centrifugalpump 1100 has the annular motor rotor 1105 which is fixed to theimpeller 1110 so that both the motor rotor 1105 and the impeller 1110rotate.

The motor stator 1106 radially surrounds the pump diffuser 1108 and thepump impeller 1110. In other words, the motor stator 1106 radiallysurrounds (encloses) the centrifugal pump. In some examples, both themotor rotor 1105 and the motor stator 1106 radially surround the pump.Thus, in those examples, the motor radially surrounds (radiallyencloses) the pump.

Moreover, as mentioned, the impeller 1110 is mechanically coupled to themotor rotor 1105. In operation, permanent magnets on the motor rotor1105 engage the motor stator 1106 for rotation of the motor rotor 1105and the impeller 1110.

The diffuser 1108 may be characterized as an internal diffuser 1108 inthat the diffuser 1108 is adjacent the shaft 1104. The impeller 1110 maybe characterized as an external impeller 1110 in that the impeller 1110is adjacent the motor rotor 1105, or in the sense that at least aportion of the impeller 1110 is radially to the outside of the internaldiffuser 1108. Both the impeller 1110 and diffuser 1108 each havemultiple vanes, though the vane geometries can be different.

The depiction in FIG. 11 is a simplified representation for clarity.While the internal diffuser 1108 may have a shape or features of animpeller, the diffuser 1008 vane geometry is configured to promotehydraulic flow and for pump efficiency. The external impeller 1110 mayhave a shape or features of a diffuser but the impeller 1110 includingits flow path and vane geometry promote hydraulic flow and pumpefficiency. A function of the external impeller 1110 may to acceleratethe pump fluids to provide the fluids with kinetic energy. A function ofthe internal diffuser 1108 may be to slow down the fluids and transferthe kinetic energy to pump head or pressure.

FIG. 12 is a motorized pump 1200 as a multi-stage centrifugal pump andwith an external rotor topology to increase the OD of the pump portion.The motorized pump 1200 has an outer housing 1202. A motor stator 1204is at the radial center of the motorized pump 1200. In examples, themotor stator 1204 has laminations and windings. Moreover, as depicted,the centrifugal pump may radially surround (radially enclose) the motorstator 1204. The motorized pump 1200 includes a pump having pumpimpeller 1206 with permanent magnets 1208 that engage the motor stator1204 in operation for rotation of the impeller 1206. Thus, that portionof the impeller 1206 with the permanent magnets 1208 may becharacterized as a motor rotor. Therefore, in examples, the pumpimpeller 1206 and the motor rotor 1206 are integrated as a single itemor component of the motorized pump 1200. Further, the motorized pump1200 has a diffuser 1210 with a flow path for the pumped fluid. Inoperation, the rotating impeller 1206 may interface with stationarydiffuser 1210.

To increase the pump portion OD, the external rotor motor topology canbe used for multi-stage centrifugal pumps, for example, as depicted inFIG. 12. In the illustrated embodiment, the permanent magnets 1208 aredisposed on at least a portion of the impeller 1206 which is magnetic.In some embodiments, with this motor topology, the permanent magnets1208 are in close proximity to the motor stator 1204 magnetic fields.The permanent magnets 1208 may be within 0.2 to 5 millimeters (mm) ofthe motor stator 1204. The pump 1200 has a power cable 1212 to supplypower to the pump 1200, such as from the surface with the pump 1200employed downhole as an ESP motor/pump.

FIG. 13 is a motorized pump 1300 as a multi-stage centrifugal pump. Themotorized pump has an outer housing 1302. In addition, the motorizedpump 1300 has a motor having a motor rotor 1301 and a motor stator 1304at the center. Moreover, as depicted, the motor is radially surrounded(radially enclosed) by the centrifugal pump or pump portion. Permanentmagnets 1308 are disposed on the motor rotor 1301 for the rotor 1301 tooperationally engage the stator 1304 such that the rotor 1301 rotates inoperation.

The rotor 1301 is mechanically coupled with the pump impeller 1306 suchthat impeller 1306 rotates with the rotor 1301. The motorized pump 1300has the centrifugal pump including the impeller 1306 and a pump diffuser1310. As indicated, the motor rotor 1301 is internally-radiallymagnetically coupled in operation with the motor stator 1304 andexternally-radially mechanically coupled with the pump impellers 1306.In sum, the motorized pump 1300 is a multi-stage centrifugal pump withan external rotor topology, and pump impellers 1306 installed on motorrotor 1301.

FIG. 13A is a representation of an exemplary pump hydraulic component1320 for the motorized pumps of the preceding figures. For example, thepump hydraulic component 1320 may be the pump impeller 1306 of themotorized pump 1300 of FIG. 13, the pump impeller 1206 of the motorizedpump 1200 of FIG. 12, internal diffuser 1108 of the motorized pump 1100of FIG. 11, the internal diffuser 1108 of the motorized pump 1000 ofFIG. 10, and so on. A function of the hydraulic component 1320 as animpeller may be to accelerate the pump fluids to provide the fluids withkinetic energy. A function of the hydraulic component 1320 may be toslow down the fluids and transfers the kinetic energy to pump head orpressure.

The pump hydraulic component 1320 may be associated with motorized-pumpcentral component 1322 such as shaft or other central componentsdepicted in the preceding figures. The pump hydraulic component 1320includes hydraulic elements 1324 such as blades or vanes. Further, inthe illustrated example, the pump hydraulic component 1320 includes afront plate 1326 and optionally an outer shroud 1328. Lastly, while thedepiction in FIG. 13A may resemble an impeller, the hydraulic elements1322 (vanes) and associated flow paths can be configured as a diffuserthat transfers the kinetic energy to pump head.

Variations of the motorized pumps of the preceding figures may beimplemented. The motor stator and motor rotor can each be fullyencapsulated to allow the air gap between them open to well fluids.Another option is to close the air gap and fill with dielectric oil. Inthe latter case, dynamic seals and elastomeric bags or metal bellows canbe used for oil expansion and contraction. Pump axial thrust can behandled either at one location or at multiple locations.

Further, a sensor unit can be added to measure operating conditions. Oneor more sensors can be added to acquire data such as downhole pressure,temperature, vibration, pump fluid intake pressure and temperature, pumpfluid discharge pressure, and other pump monitoring data. A downholesensor can be attached to the motorized pump to transmit informationsuch as intake pressure, intake temperature, motor temperature, motorvibration, etc. such as via the main power cable to the surfacecontrols.

In summary, embodiments of the present techniques are a motorized pumpwhich may have an integral motor rotor and pump rotor, and/or anexternal rotor motor. ESP reliability and rigless deployment may beaddressed. The motorized pumps discussed above including with respect tothe preceding figures may be employed as subsurface or downholecomponent(s) of an ESP, and may be coupled to or otherwise associatedwith ESP surface components. As discussed, the ESP surface componentsmay include a motor controller which may be a fixed-speed controller orvariable-speed controller, or other type of controller. The ESP systemcan include a variable frequency controller so that the ESP operatesover a broader range of capacity, head, and efficiency. The speed of anESP motor may be proportional to frequency of the electrical powersupply. Thus, by adjusting the frequency, the speed can be adjusted,which may be a purpose of the variable speed system. Therefore, if theproduction capacity of a well is not precisely known, a variable speedcontroller can be selected for an estimated range of and adjusted forthe desired production level once more data is available. Motorcontrollers may be digital controls having a system unit that performsshutdown and restart operations, and can be mounted, for example, in thelow-voltage compartment of the control panel. In some examples, motorcontrollers may also include a display unit. This unit may displayreadings, set points, alarms, and so forth.

The wellhead and accessories may be based on casing size, tubing size,recommended load, surface pressure, and setting depth. Servicingequipment may include cable reels, reel supports, and cable guides. Abottom hole sensing device or downhole sensor may provide for continuousor substantially measurement of parameters such as bottom hole pressure,wellbore pressures, wellbore or ESP temperature, discharge flow rates,water contamination of the motor, equipment vibration, and automaticwell monitoring. The aforementioned motor controllers may be availablefor the continuous monitoring of pump operations from a centrallocation.

FIG. 14 is a method 1400 of operating an ESP or ESP system having amotorized pump with an integrated motor and pump. At block 1402, thesubsurface components of the ESP are lowered into a wellbore. Forinstance, the ESP subsurface components, such as the motorized pump,while at the surface may be attached to the downhole end of a tubingstring for deployment, and then lowered into the wellbore along with thetubing.

After being lowered (block 1402) into the wellbore and situated foroperation, the well fluid to be pumped may be received (block 1404), forinstance, from the Earth or formation through perforations in the wellcasing. The fluid may include hydrocarbon such as oil and gas, as wellas contaminants and other compounds or production fluids. The action ofthe ESP lifting or pumping the well fluid or production fluid may becomposed of the actions of blocks 1404, 1406, and 1408.

At block 1404, the fluid to be lifted or pumped is received at an inletof the ESP pump and into the pump. The inlet may be a fluid intake orfluid suction, and may have a screen in certain examples. At block 1406,the ESP pump applies and imparts pump head to the pumped fluid. The ESPmay provide pump head for the total dynamic head (TDH) to lift or pumpthe desired weight or volumetric capacity of production fluid. In someexamples, the TDH may be or include the height in feet or meters offluid being pumped. The applied head may include head to overcomefriction losses in the production tubing and surface piping, and toovercome elevation changes.

At block 1408, the ESP discharges the pumped fluid through a productionconduit to the surface. Lastly, the dashed line 1410 is denoted for someexamples in which the method 1400 of FIG. 14 represents two generalactions or methods. In other words, in those examples, a first actionmay be to lower 1402 the ESP subsurface components into a wellbore. Asecond general action may be to perform the pumping acts indicated inblocks 1404, 1406, and 1408.

An embodiment includes a method of operating an ESP that is a motorizedpump, the method including pumping, by the motorized pump, fluid from awellbore. The motorized pump has a motor and a pump that radiallyencloses the motor, wherein the motor has a motor rotor and a motorstator, and wherein the pump has a pump rotor with vanes integrated withthe motor rotor. In some examples, an outer diameter or external surfaceof the motor rotor has the pump vanes giving the integral motor rotorand pump rotor. The pump may include a pump stator having vanes, whereinthe pump stator vanes and the pump rotor vanes are radially outside ofthe motor stator.

The motor stator may typically have windings. The motor rotor may havepermanent magnets and steel laminations, and wherein the pumpinginvolves electromagnetic interaction between the motor stator magneticfields and the permanent magnets, generating torque and rotation.Moreover, in examples, the ESP system or ESP motorized pump does notinclude a motor protector or ESP protector, or protection seal section.

The method may include lowering the motorized pump into the wellbore.The pumping may include receiving the fluid at an inlet suction of themotorized pump from perforations in a casing of the wellbore. Thepumping may include lifting the fluid from the wellbore and dischargingthe fluid through a production conduit to an Earth surface. The fluidmay include may include well production fluids, hydrocarbon, as oil andgas, etc.

The pumping may involve magnetic coupling between the motor and pump,wherein as the motor rotor and the pump rotor rotate, the vanes engagehydraulically with corresponding vanes on a stationary pump stator,moving pumped fluids. In certain examples, the motor stator haslaminations, slots, and magnet wires with windings of the magnet wiressuch that electromagnetic fields project outward for engagement with themotor rotor that is an external motor rotor. The motorized pump may havea radial bearing disposed axially between two adjacent stages. Lastly,in a particular example, the motor (rotor) is a squirrel cage inductionmotor (rotor).

As indicated, an ESP legacy system may include a seal section or motorseal disposed between the pump and motor. However, as also indicated,such is not employed in certain embodiments of ESP motorized pumps ofthe present techniques. The seal section may be a protector, equalizer,balance chamber, and the like. The protector may be a labyrinthprotector, bag protector, and so on. The protector may protect the motorfrom the well fluid, and provide pressure equalization between theconventional motor and the wellbore. The protector between the legacymotor and pump intake generally isolates the motor from the well fluidand may surround a thrust bearing. The seal section may protect themotor from contamination by well fluid, absorb thrust from the pump, andequalize pressure between the wellbore and motor. In all, conventionalESP systems may have a seal section or protector located between themotor and pump intake, and configured to perform one or more of thefollowing: (1) house the thrust bearing that carries the axial thrustdeveloped by the pump; (2) isolate and protect the motor from wellfluids; (3) equalize the pressure in the wellbore with the pressureinside the motor; and (4) compensate for the expansion and contractionof motor oil due to internal temperature changes. Seal sections can beused in tandem configurations for motor protection and may be availableas bag type or labyrinth-style to meet specific applications. Again,however, such seal sections or protectors are not employed in certainembodiments of the present ESP motorized pumps disclosed herein.

In applications with higher gas/oil ratios (GOR), the well fluid maycontain significant amounts of free gas. A gas separator to separate thegas from the well fluid before the well fluid enters the pump may beadded to or replace the intake section in such applications. However, asmentioned, a gas separator or compressor may not be needed with the ESPpump as a helico-axial pump. After all, the multi-stage helico-axialpump at relatively high speed can handle (process, pump) fluids havinghigh free-gas content. Indeed, the helico-axial pump itself inparticular examples may act as a compressor with respect to certainaspects. Yet, some ESPs may include a gas handler or gas separator at ornear (or combined with) the pump intake or inlet. Gas separators may beemployed where free gas causes interference with pump performance. Thegas separator may separate some free gas from the fluid stream enteringthe pump to improve pump performance. However, in some examples of thepump as a helico-axial pump with no radial or mixed-flow pump, a gasseparator is not employed. Indeed, some ESP embodiments with thehelico-axial pump and permanent magnet motor (PMM) giving higherrotation speed (for example, at least 4500 rpm) do not have this gasseparator because the need for such a gas separator may be precluded. Inother words, significant benefit may not be realized with the gasseparator in those particular examples.

In summary, an embodiment includes a motorized pump having a motor and apump. In this embodiment, the pump surrounds the motor. The motor is anexternal rotor motor. The pump rotor (having vanes) is integrated withthe motor rotor. Thus, the motor rotor and pump rotor may rotatetogether, the pump rotor to rotate within the pump stator. The pumpstator having vanes on an inside diameter to engage with the pump rotorvanes to pump fluids. In one example, an outside diameter (OD) of themotor rotor is constructed with or integrated with the pump rotor. Themotor rotor and pump rotor share a same rotor. In certain examples, themotorized pump is an ESP motor and pump and does not have an ESP motorprotector, and wherein the motorized pump includes radially, from insideto outside, the motor stator, the motor rotor and the pump rotor, thepump stator, and a housing. Again, the pump may radially enclose themotor. In some examples, the motorized pump does not have a shaftcoupling the motor to the pump. In particular examples, the motorizedpump does not have a pump diffuser. Moreover, the motorized pump may beconfigured for deployment downhole riglessly with a power cable insidetubing. In examples, the motor rotor has permanent magnets and steellaminations. The steel laminations may have the permanent magnetsmounted on an inside diameter (ID) portion, or embedded within, toengage electromagnetically with the motor stator. On the other hand, themotor rotor can be an induction type having steel laminations withcopper bars and end ring. The motor stator may be at the radial centerof the motorized pump, and wherein permanent magnets of the motor rotorand the vanes of the pump rotor are both on laminations of the motorrotor. In particular examples, the motorized pump does not have an outerhousing.

Another embodiment is a motorized pump to pump fluid, including: a shaftdisposed in a center portion of the motorized pump; a motor including amotor stator having laminations and windings; and a pump having aninternal diffuser and an external impeller, wherein the motor statorradially surrounds the pump. The motorized pump has a housing radiallyenclosing the motor stator, the internal diffuser, and the externalimpeller, wherein the motor stator is disposed adjacent the housing. Inexamples, the pump is a multi-stage centrifugal pump, and wherein themotorized pump is an ESP motor and ESP pump and does not comprise an ESPmotor protector. In some examples, the external impeller has permanentmagnets to engage the motor stator via electromagnetic coupling torotate the external impeller about the shaft, the external impellercomprising a flow path for fluid pumped by the motorized pump. Thepermanent magnets of the external impeller may form a motor rotor of themotor. In other examples, the motor has an annular motor rotormechanically coupled to the external impeller, the annular motor rotorhaving permanent magnets to engage the motor stator to rotate theannular motor rotor and the external impeller about the shaft. In thoseexamples, the permanent magnets may engage magnetic fields of the motorstator generated by electrical power delivered to the motor via a powercable, and wherein the motor radially encloses the pump. Inimplementations, the internal diffuser is disposed adjacent the shaftand has a hydraulic protrusion such as a vane or blade.

Yet another embodiment is a motorized pump including: a shaft disposedat a center portion of the motorized pump; a motor including a motorstator having laminations and windings; a pump that is a multi-stagecentrifugal pump having multiple hydraulic stages, each stage includingan internal diffuser and an external impeller, the external impeller forfluid pumped by the motorized pump; and a housing radially enclosing themotor stator, the internal diffusers, and the external impellers,wherein the motor stator radially encloses the pump. In examples, theinternal diffuser has a vane or blade. In implementations, the externalimpeller has permanent magnets to engage the motor stator viaelectromagnetic coupling to rotate the external impeller about theshaft. In certain examples, the motor has an annular motor rotormechanically coupled to the external impeller, the annular motor rotorhaving permanent magnets to engage the motor stator via electromagneticcoupling to rotate the annular motor rotor and the external impellerabout the shaft. In examples, motor radially surrounds the pump. In someimplementations, the motor has an annular motor rotor comprisingpermanent magnets to engage the motor stator via electromagneticcoupling to rotate the annular motor rotor around the shaft, wherein theexternal impeller is mechanically coupled to the annular motor rotor torotate with the annular motor rotor around the shaft, and wherein theannular motor rotor has steel laminations. In certain examples, themotorized pump is an ESP motorized pump and does not have an ESP motorprotector.

Yet another embodiment is a method of operating an electricalsubmersible pump (ESP) having a motorized pump, the method includingpumping, by the motorized pump of the ESP, production fluid from awellbore, wherein the motorized pump comprises a pump and a motor statorradially enclosing the pump, the pump comprising an external impellerand an internal diffuser, wherein the pumping involves receiving theproduction fluid at an inlet of the pump, receiving the production fluidat the external impeller and rotating the external impeller around ashaft of the motorized pump, and flowing the production fluid through aflow path of the internal diffuser. In examples, the method includeslowering the motorized pump into the wellbore, wherein the motor statorhas windings, wherein the ESP does not comprise a motor protector, andwherein receiving the production fluid at the inlet involves receivingthe production fluid (for example, hydrocarbon) from perforations in acasing of the wellbore. In implementations, the pump is a multi-stagecentrifugal pump, wherein the pumping includes discharging theproduction fluid through a production conduit to an Earth surface,wherein the production fluid includes oil and gas, and wherein themotorized pump does not have a motor protector section. The rotating ofthe external impeller may be by engaging permanent magnets of theexternal impeller with the motor stator via electromagnetic coupling torotate the external impeller around the shaft. In examples, the motorhas an annular rotor motor mechanically coupled to the externalimpeller, wherein rotating the external impeller involves engagingpermanent magnets of the annular motor rotor via electromagneticcoupling to rotate the annular motor rotor and the external impelleraround the shaft, and wherein the motor radially surrounds the pump. Themethod may include receiving electricity via a power cable to the motorand generating, via the electricity, magnetic fields of the motorstator, wherein the internal diffuser is disposed adjacent the shaft andhas a vane or blade.

A number of implementations have been described. Nevertheless, it willbe understood that various modifications may be made without departingfrom the spirit and scope of the disclosure.

What is claimed is:
 1. A motorized pump comprising: a motor comprising amotor rotor and a motor stator, the motor stator comprising windings;and a pump surrounding the motor, the pump comprising a pump rotorintegrated with the motor rotor, wherein the pump rotor comprises vanes.2. The motorized pump of claim 1, wherein the motor comprises anexternal rotor motor, and wherein the pump comprises a pump statorhaving vanes on an inside diameter to engage with the pump rotor vanesto pump fluids.
 3. The motorized pump of claim 2, wherein the motorrotor and pump rotor are configured to rotate together, the pump rotorto rotate within the pump stator.
 4. The motorized pump of claim 2,wherein the motorized pump is an electrical submersible pump (ESP) motorand pump and does not comprise an ESP motor protector, and wherein themotorized pump comprises radially, from inside to outside, the motorstator, the motor rotor and the pump rotor, the pump stator, and ahousing.
 5. The motorized pump of claim 1, wherein the pump radiallyencloses the motor, wherein the motorized pump does not comprise a shaftcoupling the motor to the pump, wherein an outside diameter (OD) of themotor rotor is constructed with or integrated with the pump rotor, andwherein the pump does not comprise a diffuser.
 6. The motorized pump ofclaim 1, wherein the motor rotor comprises permanent magnets and steellaminations.
 7. The motorized pump of claim 6, wherein the steellaminations have the permanent magnets mounted on an inside diameter(ID) portion or embedded within to engage electromagnetically with themotor stator.
 8. The motorized pump of claim 1, wherein the motor rotoris an induction type comprising steel laminations with copper bars andend ring.
 9. The motorized pump of claim 1, wherein the motor stator isat a center of the motorized pump, and wherein permanent magnets of themotor rotor and the vanes of the pump rotor are both on laminations ofthe motor rotor.
 10. The motorized pump of claim 1, wherein themotorized pump does not comprise an outer housing.
 11. A motorized pumpcomprising: a motor comprising a motor rotor and a motor stator, themotor stator comprising windings; and a pump radially enclosing themotor, the pump comprising a pump rotor integrated with the motor rotor,wherein the pump rotor comprises vanes.
 12. The motorized pump of claim11, comprising permanent magnets disposed on the motor rotor, whereinradially, from inside to outside, the motorized pump comprises (a) themotor stator, (b) the motor rotor and the pump rotor, (c) a pump stator,and (d) a housing, and wherein the pump and motor are contained withinthe housing.
 13. The motorized pump of claim 11, wherein the motorcomprises an external rotor motor, wherein the motor rotor comprisespermanent magnets and radially encloses the motor stator, and whereinthe pump comprises a pump stator comprising vanes on an inside diameterto engage with the pump rotor vanes to pump fluids.
 14. The motorizedpump of claim 11, wherein the motor comprises an induction motor or apermanent magnet motor, wherein the motor stator comprises laminationsand windings, and wherein the motorized pump is configured fordeployment downhole riglessly with a power cable inside tubing.
 15. Themotorized pump of claim 11, wherein the motor rotor and pump rotor sharea same rotor, wherein the pump comprises a pump stator with vanes,wherein pump rotor vanes are machined, and wherein the motorized pumpdoes not comprise a shaft coupling the pump to the motor.
 16. Themotorized pump of claim 11, wherein the motorized pump does not comprisean outer housing.
 17. The motorized pump of claim 11, wherein the motorstator is at a radial center of the motorized pump, the motor rotorcomprising a stack of steel laminations compressed together, and withinthese laminations, slots cut for magnetic wire windings.
 18. Themotorized pump of claim 11, wherein the motor rotor is an inductionmotor comprising copper bars inside a stack of steel laminations andshort circuited with end rings.
 19. A method of operating an electricalsubmersible pump (ESP) comprising a motorized pump, the methodcomprising pumping, by the motorized pump, fluid from a wellbore,wherein the motorized pump comprises a motor and a pump that radiallyencloses the motor, wherein the motor comprises a motor rotor and amotor stator, and wherein the pump comprises a pump rotor comprisingvanes integrated with the motor rotor.
 20. The method of claim 19,comprising lowering the motorized pump into the wellbore, wherein themotor stator comprises windings.
 21. The method of claim 19, wherein thepumping comprises receiving the fluid at an inlet suction of themotorized pump from perforations in a casing of the wellbore, whereinthe fluid comprises hydrocarbon, and wherein the motorized pumpcomprises a radial bearing disposed axially between two adjacent stages.22. The method of claim 19, wherein the pumping comprises lifting thefluid from the wellbore and discharging the fluid through a productionconduit to an Earth surface, wherein the fluid comprises oil and gas,and wherein the motorized pump does not comprise a motor protectorsection.
 23. The method of claim 19, wherein an outer diameter orexternal surface of the motor rotor comprises vanes giving an integralmotor rotor and pump rotor, wherein the pumping comprises magneticcoupling between the motor and pump to move pumped fluids, wherein asthe motor rotor and the pump rotor rotate, the vanes engagehydraulically with corresponding vanes on a stationary pump stator tomove the pumped fluids, wherein the pumped fluids comprise productionfluids.
 24. The method of claim 19, wherein the motor stator compriseslaminations, slots, and magnet wires with windings of the magnet wiressuch that electromagnetic fields project outward for engagement with themotor rotor comprising an external motor rotor.
 25. The method of claim19, wherein the pump comprises a pump stator comprising vanes, whereinthe pump stator vanes and the pump rotor vanes are radially outside ofthe motor stator, wherein the motor rotor comprises permanent magnetsand steel laminations, and wherein the pumping comprises electromagneticinteraction between the motor stator magnetic fields and the permanentmagnets generating torque and rotation.
 26. The motorized pump of claim19, wherein the motor rotor comprises a squirrel cage induction motor.